HP-C 509 Version 2010 - Supplier Quality Manuals

1 HP-C 509 Version 2010 . 1. Introduction A world of continuously changing customer expectations and worldwide competition requires continuous improvement of all products and services as well as business processes and corporate procedures. Customer satisfaction through Quality in all aspects is a crucial success factor for HELLA as a Supplier of complex products for the international automotive industry and consequently for you as our contractor (termed Supplier hereafter), whose products are used in Hella assemblies. The achievement of zero-defects Quality for all supplies is an absolute prerequisite which can only be achieved and secured through the common efforts of Hella and its suppliers: Avoiding defects instead of discovering defects and continuous improve- ments in the entire supply chain, customer inquiry, offer, order, product devel- opment, start of production, volume deliveries and field operation are indispensable requirements which we must and want to fulfil with the active help of our suppliers.

2 This guideline highlights Hella's requirements for suppliers and also refers to the valid international standards, methods and implementation instructions ( by VDA) which are necessary to achieve common objectives. This makes it possible to implement a common Quality strategy, to guarantee a smooth workflow between our suppliers and Hella and to minimize costs. Area of application The guideline is binding for all products and services supplied by a Supplier to Hella KGaA Hueck & Co, or to a company associated with Hella where Hella has the majority share and is part of Framework Supply Agreement for the procurement of manufacturing materials , Hella General Terms of Purchasing or comes into op- eration by individual agreements. Martin Jungbluth Dr.

3 Christof Hartmann Head of Corporate Purchase Management Head of Corporate Quality Management 2. Hella's Quality and environmental policies The following extracts from Hella's Quality and environmental policies should pro- vide the Supplier an orientation which focus is to be considered with regard to these subjects. The benchmarks for Hella's actions are customer satisfaction through first-class Quality of all products and services, as well as cooperative work and a high level of expertise. The zero defects Quality of our products, actions and services, combined with ex- pertise, innovation and internationalism, will secure the satisfaction of all customers in the long term, and thus our competitiveness. Hella Quality policy Quality is the no-compromise fulfillment of all product characteristics and work pro- cedures agreed with the customers.

4 The target is zero defects for delivered Quality during the product life and for all Hella services. To secure these claims and to guarantee customers consistently high Quality in every respect, we plan Quality down to the last detail during the development of product- and manufacturing proc- ess, using carefully chosen methods. This planning procedure is carried out inde- pendently of whether production is later to take place on Hella premises or at the suppliers, and includes all substances and materials used, of course. After SOP, the serial Quality of the product is assured and continually improved by means of ac- companying Quality observation and control. Meeting customer requirements and fulfilling internal Quality targets have the high- est company priority.

5 We also expect this procedure from our suppliers, who have to have an effective, successful Quality management system available. Hella environmental policy Hella is committed to protecting the environment. In order to implement this envi- ronmental policy, Hella has had its plants certified according to ISO 14001[1]. We require our suppliers to meet the relevant valid environmental legislation. We expect effective environmental management from our suppliers, which guarantees adher- ence to the relevant valid environmental regulations and improves the Supplier 's environment situation continuously and efficiently. On request, the Supplier must be able to demonstrate appropriate waste-avoidance, recycling and disposal concepts for both products and packaging.

6 Proof is recommended in the form of a certified environment management system. 3. Quality management A correlation between the Supplier 's organizational and technical prerequisites and Hella's Quality requirements is the basis for a successful business relation- ship. In detail, Hella requires the following from suppliers: Quality requirement as In order to meet the high expectations of the automobile industry, Hella trusts the a condition for delivery performance and commitment of its own employees to a large extent, and expects the same attitude towards employees and partners from its suppliers. This is a major precondition for the Quality capability the Supplier has to prove. Supplier activity Hella activity Obligation of proof towards Hella Quality requirement levels Actions/prerequisites Methods, documents Corporate culture Co-operative, target-oriented Completion and follow-up of di- management vision-related target agreements Promotion of initiative and crea- Delegation of responsibility and tion of opportunities for personal competence development of the employees Qualification of employees and training in tools, methods and promotion of Quality conscious- standards see , ness Support in solving Quality prob- lems Requirement-based employee assignment Management system ISO 9001:2008 Certification by a third party Implementation of a Quality Management system according to ISO/TS 16949 requirements.

7 ISO/TS 16949 training and application ISO 14001 Environment management activ- ity or certification by a third party Further development of an ef- Management Manual fective procedural organization Creation of organizational and CAQ system technical requirements for col- lecting and evaluated Quality in- formation Quality assurance Avoiding faults Small Q-control loops Systematic processing of faults Problem-solving techniques Avoiding repeat faults Cause-effect analysis Feedback to development and engineering change process Audits Regular internal audits System Process Product Continuous improvement Introduction and maintenance Employee training process for all products, processes and Programs, targets and reviews services Supplier development Cooperation on partnership Exchange of information basis Joint project work Implementation of training ses- sions, providing methods Quality planning and Advanced Quality planning carefully designed to avoid faults during product and cooperation process development ensues that only technically mature products are produced using capable production processes.

8 Quality planning levels Actions/prerequisites Methods, documents Definition phase Requirement specification Definition of requirements Schedule and cost frame Preparation of inquiry Inquiry phase Selection of potential suppliers Meeting minimum Supplier re- quirements System audit if appropriate Evaluation of capability Inquiry Inquiry documents Concept preparation Determination of Hella expecta- Analysis of requirement specifi- tions cation Check of specification, deadline Revision of contract and pricing Feasibility study QFD. Benchmark analysis Quotation phase Preparation of a binding quota- Performance specification /. tion deadlines / prices Placing orders Analysis of quotation Checklists Placing of orders with suitable Binding order documents, speci- suppliers fications, deadlines, prices Implementation of concept Integration in Hella project team Advanced Quality planning Control Plan / Production Steer- ing Plan Process audit Estimation of Quality risks Product/Design FMEA.

9 Fault tree analysis/risks Development Monitoring and evaluation of Design review design drafts and prototypes Sturdy design Design for manufacturing /Assembly Design for reliability Checking manufacturability Trial planning Production preparation Estimation of possible produc- Process FMEA. tion risks Optimization of production Operational test run methods and operating equip- Trial planning ment, packaging Test planning Pre-series Checking and evaluating pro- Analysis and proof of capability duction reliability for testing equipment, machines and processes Full-Run test / process audit Cleanness requirement accord- ing to specification Minimization of probability of Plans of Action faults Series production start-up Series production approval at Measurement sequence and phase suppliers SPC.

10 Process release Initial sample inspection report /. PPAP. Define limit samples Release of supply phase Release by Hella Release report Supplier assessment Q-performance, flexibility, deliv- ery reliability, cooperation Quality control in The Quality assurance actions in the series production are based knowledge Supplier 's series gained during the development phase and observation of the field use of compa- production, conditions rable products, and are used to consolidate and continuously improve the level of for delivery Quality achieved. Self-regulating processes and automated tests should be used wherever it makes technical and economical sense. Employee Quality responsibility must be further developed in line with technical progress and customer expectations.